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Composite Tension Rod Insulator
Factory: We are a professional manufacturer providing OEM custom production services.
- Product Overview
- Technical Specifications
- Product Structure
- Applications
- Testing Capability
- Packaging & Customization
Product Overview
Wishpower composite tension rod insulators are designed for applications that require both electrical isolation and mechanical tension resistance. The fiberglass core carries the axial mechanical load, while the silicone rubber housing provides external insulation and environmental protection.
The main advantages of Wishpower tension rod insulators include:
High-temperature vulcanized silicone rubber housing with good hydrophobic properties.
High-strength fiberglass-reinforced epoxy core for axial tensile loads.
Lightweight construction for easier transportation and installation.
Corrosion-resistant end fittings for humid, coastal and industrial environments.
Flexible shed profiles for different creepage-distance requirements.
Customizable voltage rating, tensile load, connection size and installation length.
Stable performance under vibration and repeated mechanical stress.
Wishpower can design tension rod insulators according to the electrical system, catenary structure, available installation space, mechanical load and applicable project standards.
Core Features
Reliable Electrical Insulation
The optimized shed profile increases creepage distance and helps maintain insulation performance under rain, moisture and surface contamination.High Mechanical Tensile Strength
The fiberglass core carries the main axial load and provides stable mechanical performance under continuous tension, vibration and short-duration impact.Resistance to Pollution Flashover
Silicone rubber offers hydrophobicity and hydrophobicity recovery, helping reduce the formation of a continuous conductive water film.Lightweight Composite Construction
Composite tension rod insulators are lighter than comparable porcelain components, reducing the load on supporting structures and simplifying installation.Weather and Corrosion Resistance
The housing and metal fittings can withstand ultraviolet radiation, rain, temperature variation, salt fog and industrial contamination.Flexible End-Fitting Designs
End fittings, mounting holes, overall length and interface dimensions can be manufactured according to equipment drawings.Reduced Maintenance Requirements
The non-brittle composite housing reduces breakage risk, while routine maintenance normally focuses on visual condition, fittings and mechanical connections.
Product Structure
A Wishpower composite tension rod insulator normally consists of the following components:
Fiberglass Core Rod
The fiberglass-reinforced epoxy rod is the principal mechanical load-bearing component and carries axial tensile force.Silicone Rubber Housing
The housing covers the core rod and provides external insulation, moisture protection, pollution resistance and weather resistance.End Fittings
Metal fittings are installed at both ends for connection to rods, brackets, catenary components or other electrical equipment.Crimping Area
A controlled crimping process connects the metal fittings to the fiberglass core and ensures reliable transfer of mechanical loads.End Sealing System
The interface between the housing, core and fittings is sealed to prevent the ingress of moisture, dust and corrosive contaminants.Optional Protection Accessories
Depending on the voltage level and application, the product may be supplied with grading rings, arcing protection devices or other accessories.
Technical Specifications
| Parameter | Application Range |
|---|---|
| Product Name | Composite tension rod insulator |
| Rated Voltage | Customized for railway, urban rail or power system requirements |
| System Type | AC or DC system |
| Housing Material | High-temperature vulcanized silicone rubber |
| Core Material | Fiberglass-reinforced epoxy resin |
| End-Fitting Material | Hot-dip galvanized steel, stainless steel or customized alloy |
| Specified Mechanical Load | Customized according to installation and mechanical requirements |
| Section Length | Customized according to equipment dimensions |
| Creepage Distance | Designed according to system voltage and pollution level |
| Shed Profile | Equal-diameter sheds, alternating sheds or customized profile |
| Connection Type | Clevis, eye, tongue, socket or drawing-based design |
| Installation Environment | Indoor, outdoor, tunnel, coastal or industrial area |
| Ambient Temperature | Designed according to project conditions |
| Altitude | Standard-altitude or high-altitude design |
| Corrosion Protection | Hot-dip galvanizing, protective coating or stainless-steel fittings |
| Applicable Standards | IEC 61109, IEC 62217 or project-specified standards |
| Customization Options | Voltage, length, creepage distance, fittings and tensile load |
Product Structure
Main Applications
Wishpower composite tension rod insulators can be used in:
Electrified railway catenary systems
Railway traction power supply systems
Metro power supply systems
Light rail and urban rail transit networks
Insulated catenary tension-rod assemblies
Rigid overhead conductor systems in tunnels
Traction substations
Railway disconnector support or connection assemblies
High-pollution railway corridors
Coastal rail power infrastructure
High-humidity transportation environments
The final application depends on the rated voltage, mechanical load, structural dimensions, end fittings and project design requirements.
Testing Capability
Depending on the product model, procurement specification and project requirements, Wishpower tension rod insulators can be inspected and tested for the following items:
Visual Inspection
The silicone rubber housing, end fittings, sealing areas and product surface are checked for cracks, deformation, incomplete molding or mechanical damage.Dimensional Inspection
Section length, fitting dimensions, hole diameter, shed dimensions and creepage distance are verified against approved drawings.Mechanical Tensile Load Test
The test verifies the mechanical integrity of the core rod, end fittings and crimped connection under the specified load.Power-Frequency Withstand Voltage Test
The test evaluates insulation performance under the specified power-frequency voltage.Lightning Impulse Withstand Test
Where applicable, the product is tested for its ability to withstand impulse overvoltage.Wet Power-Frequency Test
This test evaluates external insulation performance under wet or simulated rain conditions.Sealing Inspection
The end-sealing system is checked to reduce the risk of moisture entering the core-to-fitting interface.Galvanizing or Coating Inspection
The corrosion-protection layer is inspected for coverage, uniformity and surface condition.Material Performance Tests
Silicone rubber, fiberglass core and metal materials can be verified according to the applicable technical specification.Routine Factory Inspection
Each production batch is subject to the specified visual, dimensional, mechanical and electrical quality checks.
Packaging & Transportation
To keep products safe during transportation and storage, we use the following packaging methods:
- Individual Packaging: Each product is wrapped with protective film, packed in a high-strength carton, and cushioned with buffer materials.
- Pallet Packaging: Multiple products are fixed on wooden pallets and wrapped with stretch film, suitable for container shipping.
- Export Packaging: Fumigated wooden cases, moisture-proof treatment, and detailed packing lists are provided according to sea freight requirements.
Customization Service
WishPower can provide the following customization options according to customer requirements:
- Structural Dimensions: Adjust overall height, creepage distance, shed quantity, and shed diameter.
- End Fittings: Customize ball-socket, tongue-clevis, eye, or other interface types according to connection requirements.
- Color: Standard gray, with red, yellow, blue, and other colors available subject to MOQ.
- Special Environments: Formulations for extreme cold (-60 C), strong UV exposure, heavy pollution, and other harsh conditions.
- Voltage Classes: Full-range customization from 10kV to 1000kV.
- Marking: Customer logos or model numbers can be molded or printed on the product.
For specific customization requirements, please contact our sales engineers. We will provide a technical solution within 24 hours.
FAQ
Q: Can you supply complete products for transmission and distribution projects?
A: Yes. We can provide composite insulators, surge arresters, fuse cutouts, insulating bushings and related power insulation products.
Q: Are composite insulators suitable for coastal areas?
A: Yes. Composite insulators with silicone rubber housing provide good hydrophobicity and anti-pollution performance, making them suitable for coastal and polluted environments.
Q: Can you provide customized insulation products?
A: Yes. WishPower supports customized voltage ratings, creepage distances, fittings, colors and drawings according to project requirements.
Q: What information should I provide for a quotation?
A: Please provide voltage level, product type, quantity, application environment, standard, drawings or technical specifications if available.
Q: How do I choose the right composite insulator for my project?
A: You can provide voltage level, installation type, mechanical load, creepage distance and operating environment. Our team will recommend the suitable model.
